In this instructable (My very first-able) I'm going to show how I made a replacement handle of a espresso cofee tamper from wood after the original made from PVC broke.
First I'm not a carpenter nor I have much experience in woodworking but I think I can do good.
Before starting to tell what tools should you use, I must tell you that I didn't have a wood lathe which is the most important tool in making this wood coffe tamper handle, so I made some removable parts, attachable to any drill press ( I'll make another instructable for this).
Tools You'll Need:
- Wood chisel (very sharp one, about 1 1/8 large)
- Drill press and the removable parts attached to it in order to make the lathing possible.
- A rotary tool with a variation of carbide burrs, disks and bits (you can do without these by only using chisel)
- A drill
- Drill bits and forstner bits
- Caliper micrometer (very useful but you can make it somehow without it )
- Handsaw or miter saw
Desk Grinder (to round out the nut)
Materials You'll Need:
- A piece of hardwood ( I used red oak)
- Sandpapers ( 120,150,220,330)
- Tung Oil ( you can use anything you like for finish)
- Lint free clothe for oiling
- Stainless steel nut or if you have right size thread maker you can make thread directly into wood hole
- Rapidfix Glue to glue the nut inside ( you can use equivalent but Rapidfix really rocks)
Step 1: Find a Piece of Hardwood
Find a piece of wood and cut it about 2 inches longer than the height of the original handle. Use miter saw to have a straight cut
Step 2: Install the Removable Parts to the Drill Press
Attach the removable parts to drill press and make sure both the top and bottom are aligned.
Step 3: Start Giving Shape
After installing the piece of wood turn the drill on and using the tools like chisel, carbide burrs, disk etc., start giving the desired approximate shape. Remember to always back chisel on right side of the toolrest otherwise you'll probably scrap the piece of wood and hurt yourself.
Step 4: Finalizing the Shape
Use mostly chisels to give the final shape and then use sandpapers for a smooth surface.
Step 5: Finish
Use tung or linseed oil ( or simply varnish if you don't have oil) for the finish applying it with a lint free cloth. You can apply three thin film, two hours preferably between each coat.
Step 6: Round the Nut Out
Because of the lack of space in the bottom body part of the handle, the nut must be turned out to round shape and removing as much as possible from it.
Step 7: Make the Opening for the Nut
Using the drill press and a forstner bit about 3mm larger than the nut, make a hole in the middle of the bottom of the handle. Make sure to hold tight and straight while drilling.
Step 8: Mount the Nut Inside the Hole
Using the two component super glue called Rapidfix (one component is powder one is liquid. HOW TO USE RAPIDFIX: CLICK HERE) to weld the nut into the hole. You remember in the previous step when I said to make the hole about 3mm larger than the nut, well you're going to pour the powder on the gap between the wood and the nut and than pour the liquid component on top of the powder about the same amount of the powder (maybe a little bit more, but be careful not to spill the liquid nor the powder on the thread because this can make harder or impossible to screw the tamper in).